Mesh Automation

Robotic Machining with MAC

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Robotic Machining of AL with MAC Cell Case Study
Project Details

Robotic machining is best suited when the part is very large or awkward in geometry thus requiring a solution where the spindle can be taken to the part.   This coupled with a requirement needing 6 axis spindle adjustment makes for an ideal robotic application.

In this case study, the customer required a system that could machine holes and remove material in an automotive (roof rail) part made from Aluminum.   Feature accuracy was tested on 100% of products made using a quality fixture and was required to be within .009” of the target.

MESH used their Generation II MAC cell as the base technology and provided a customized operator interface, machining spindle, and semi-automated fixture to satisfy the customer’s cycle rate (60-120 seconds depending on part) and quality parameters.

Fixture Design

Fixture design was an important part of the system due to the large quantity of parts that the customer was processing per day, ergonomics and the short part runs.

The fixture designed and built by MESH included a two-station rotary system with automated clamping features.  Two parts were unloaded and loaded while two parts were being machined on the robot side of the system.

Buffing and Tool Changeout
  • The spindle used in this machine was a liquid cooled 8KW servo with a HSK40E tool changer. Four HSK40E tools were provided with 2 station tooling stand to hold the various machining tools needed for the job.
  • The robot in this cell was an IRB 4400 60kg, 1.96m reach specified with SafeMove II, Absolute accuracy and other options for use in machining
  • A cleaning station and recalibration station were provided to keep the system running and for ease in troubleshooting.